OEM Sustainability: Energy Efficiency for Machines

Purchase price of a machine accounts for just 2%-3% of its overall cost. Making intelligent choices when choosing motors can save up to 30% of energy consumption over the life of a machine.


Industry and infrastructures consume more than 31% of available energy globally, with electrical motors alone representing more than 60% of this amount. With the increasing cost of electricity, intelligent consumption is a major concern for users and manufacturers.

(1) Using a motor with higher efficiency saves up to 10% energy. (2) A variable speed drive to control a motor saves up to 50%. (3) Using a servo drive and synchronous motor brings an additional 30% of savings, compared to standard drives in positioning a

When a decision is made to acquire a new machine, a manufacturer should consider the amount of energy that will be consumed by this machine during its lifecycle. Among expenses from the acquisition to dismantling of a machine, the purchase price accounts for 2% to 3% of the overall costs; the remainder is mainly its energy consumption. Smart solutions exist today to make the most of the available energy.

Machine engineering can be a key source of improvement in the energy consumption of machines. A machine is designed according to performance criteria and productivity. The engineer’s goal is to find the most efficient, economic, and competitive solutions—and motor selection is the result of these choices.

Generally, the selection is finalized when the mechanical part is defined and the power consumption is typically not taken into account; however, the growing cost of energy imposes new strategies. The choice of the motor should be the starting point of any reflection to reduce the power demand. Considering the mechanical requests, the motors that will equip the machine must answer several criteria.

First, motors allow machine continuous operation and provide the needed torque at the rated speed. This first consideration determines the motor size. The designer must also consider the motor torque requested to start the machine. Eventually, the motor may have to be oversized. Duty cycle is also a key point—any time the machine is started, there is a motor heating and it is essential not to exceed a limit which, at last, will end with the failure of the motor.

Generally speaking, a motor’s energy bill is motor cost x 100. Beyond the investment, the key point is to secure an efficient motor control. During a motor’s average 15-year life, 1% of the cost is capital investment, 2% is installation and maintenance, a

The ultimate decision is based on the environmental conditions and will take into account the temperature and the altitude at which the machine is due to operate. When all these evaluations are made, the selected motor is usually larger than necessary for continuous operation. As the motor is not running at its rated power, its efficiency is reduced. That inevitably leads to increased energy consumption. Due to motor and machine efficiency, part of this energy is simply wasted.

A closer examination of the machine, its modes of operation, and dynamic performances is the best way to choose the most suitable motor technology. Making intelligent choices when choosing motors can save up to 30% of energy consumption over the life of the machine.

- Ian Hitchins is vice president of OEM solutions, Schneider Electric. Edited by Mark T. Hoske, CFE Media, Control Engineering, www.controleng.com.



No comments
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2013 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
A cool solution: Collaboration, chemistry leads to foundry coat product development; See the 2015 Product of the Year Finalists
Raising the standard: What's new with NFPA 70E; A global view of manufacturing; Maintenance data; Fit bearings properly
Sister act: Building on their father's legacy, a new generation moves Bales Metal Surface Solutions forward; Meet the 2015 Engineering Leaders Under 40
Cyber security cost-efficient for industrial control systems; Extracting full value from operational data; Managing cyber security risks
Drilling for Big Data: Managing the flow of information; Big data drilldown series: Challenge and opportunity; OT to IT: Creating a circle of improvement; Industry loses best workers, again
Pipeline vulnerabilities? Securing hydrocarbon transit; Predictive analytics hit the mainstream; Dirty pipelines decrease flow, production—pig your line; Ensuring pipeline physical and cyber security
Upgrading secondary control systems; Keeping enclosures conditioned; Diagnostics increase equipment uptime; Mechatronics simplifies machine design
Designing positive-energy buildings; Ensuring power quality; Complying with NFPA 110; Minimizing arc flash hazards
Building high availability into industrial computers; Of key metrics and myth busting; The truth about five common VFD myths

Annual Salary Survey

After almost a decade of uncertainty, the confidence of plant floor managers is soaring. Even with a number of challenges and while implementing new technologies, there is a renewed sense of optimism among plant managers about their business and their future.

The respondents to the 2014 Plant Engineering Salary Survey come from throughout the U.S. and serve a variety of industries, but they are uniform in their optimism about manufacturing. This year’s survey found 79% consider manufacturing a secure career. That’s up from 75% in 2013 and significantly higher than the 63% figure when Plant Engineering first started asking that question a decade ago.

Read more: 2014 Salary Survey: Confidence rises amid the challenges

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.